Method for building monolithic-concrete underground structures



sept 18, 1928-.

H. B. ARDEN METHOD Non BUILDING NoNoLITHIc CONCRETE UNDERGROUND STRUCTURES y Filed Oct. 1'7. 1927 4 Sheets-Sheet 1 ffm. 6mm/ms j l l Sept. 18, 1928. I 1,684,816

H. B. ARDEN M ETIflQD ,FDR BUILDING MONOLITHIC CONCRETE UNDERGROUND STRUCTURES Filed Oct. 1'7, 1927 4 Sheets-Sheet 3 @noe/M201, y

. with sept. 1s, 192s. 1,684,816 H. B. ARDEN 1 METHOD FOR BUILDING MONOLITHIC CONCRETE UNDERGROUND STRUCTURES Flved Oct. l7, 1927` 4 Sheets-Sheet 4 Patented Sept. 18, 1928.

UNITED STATES PATENT GFFICE.

HARRY B. ARDEN, or NEW YORK, N. Y.

Application led October 17, 1927. Serial No. 226,679'.

The object of my invention isto facilitate and make possible the building within' the ground of a monolithic concrete core wall,

continuously and be buttressed on elther or both sides, as often as necessity requires, and-wh1ch may be made straight or`curved'or given any other desired shape, according tothe contour required. g

Hl Other objects of my invention are to facilitate the building within the ground. of monolithic buttressed. retaining walls, piers and other concrete structures.

A further object is to provide a means l5 and method which will be largely or entirely free of manual labor, except such as is incidental to the operation of machinery.

Still another object is to provide for suit able reinforcing.

2W Thesev and other objects are accom llslied by my invention, some embodiments o which are hereinaftermore particularlyset forth.

For a more particular description of my invention, reference is to be. had to the accompanying drawings, forming a part hereof in which g Figure 1 is a side elevation of one embodiment of my interlocking form.

Figure 2 is an end view of Figure 1.

Figure 3 shows an end view of a number of these forms connected together so as to form cells.

Figure 4 shows an end view of an embodiment of Figure 2 designed to be used where a bend from a straight line is required.

Figure 5 is an end view of a form such as would be used in beginning work.

Figure 6 is a diagrammatic end view of a number of these interlocking forms in position, showing certain forms carried atright angles to the main line for the purpose of forming buttresses to a wall.

Figure 7 is a diagrammatic end view showing a double line o f t-hese forms making a sharp curve to attain a right angle direction.

Figure 8 is a view showing a number of these interlocking forms .within the ground, the ground being broken away in part to show a portion of completed concrete wall 5o and to show concrete being poured through l the bottom of a, pipe into one of the cells within'these forms.

Figure 9 shows one of these interlocking forms within the ground having a pipe carl@ ried within same at the lower end of which rogressively, which may s -forms, partially within the ground, the

is a wedge-shaped ram for ramming concrete t the bottom to provide a wider bearing surace. Figure 10 shows two of the interlocking ground being broken away in partto show completed and partially completed concrete wall with bow-shaped reinforcing rods within the concrete.

Figure 11 shows a sectional view of a con,- crete wall within the ground and a frame carried; above the ground for the purpose of extending the wall upwards above the top otf he ground and to provide a wide cap at i s op.

Figure 12 shows a sectional view of a concrete core wall projecting" above the surface of the ground and having a, broad cap at the Figure 13 is the same as Figure 12, exce t that it shows a mushroomed base to t e wall to provide greater bearing surface in soft ground.

Figure 14 is a sectional view of Figure 15 and shows a core wall in section supported by a double buttress carried down below the bottom ofthe core Wall proper, the said double buttress having its lower portion expanded,uthus serving as a pier in support of the wa Figure 15 is a side elevation of buttressed wall described in Figure 14.

Figure 16 is a side elevation, with parts broken away, showing the apparatus and its functioning.

Figure 17 is'a side elevation of a modification of the interlocking apparatus for use where certain ground conditions exist.

Figure 18 is an end elevation of Figure 17.

Figure 19 is a core used in the modification shown in Figures 17 and 18. Figure 20 is a. plan of two driving elements shown in Figure 17, without the interlocking forms.`

Figure 21 is a bottom view of one of these driving elements.

Figure`22 is an end view of the driving element, and

Figure 23 is a side view of same.

Figure 24 shows theV upper and lower ends respectively, of two interlocking forms with tie plates.

Figure 25 is a modified form of interlocking frame, with. -'different interlocking features.

f drawn,

Throughout the various views of the draw? ings, similar reference characters designate similar parts.

A general idea of my invention may be had from Figure 16 where 1 represents the earth in which the monolithic concrete core wall 2 is to be placed. This is accomplished by haivng a suitable hoisting tackle 3 elevate, connect and place a form 4 so that its lower edge projects into the earth 1. When this form has sunk as far as it will, by its own weight, the hoisting tackle is removed and another form similarly placed and connected, as above set forth. When a number of forms 4 are iii place, as indicated in Figure 16, a pile hammer, or similar device, 5 drives these forms into the earth to the required depth. This may vary from a few feet down to as much as over one hundred. When these forms are in place, the interior is excavated by means of a hydraulic or pneumatic jet passed through a'pipe 6, in the conventional manner. As each form is emptied it is preferably protected against refilling as by means of a cover, not shown.

Thereafter a trough 7, or similar instrument, guides a stream of concrete 8 into the empty form 4 and fills the same to the proper level. This concrete is soft concrete of the desired constituency, according to the nature of the soil 1, the depth to which it is to be deposited andother factors which may have a bearing on the situation. v Following the filling, the formsare within due season, as follows: At least two forms must always be'filled with this concrete before withdrawing the rear end form. This concrete is made sufficiently fluid to function properly in the apparatus so that the steps which will now be described can be carried out, thus forming the monolithic structure. At the right time and before the concrete 2 has any opportunity `to set by lapse of time, the rear end form 4 is withdrawn by the hoisting tackle 3 and when so withdrawn it is shifted forward and inserted, as above described, at

the forward end of the line. When so removed, the concrete formerly contained in this form joins with the concrete in the form next forward and becomes one integral mass with the same.

The same operation which has just above been described applies under all the conditions of service, although there are certain modifications that are sometimes required for special conditions, as will appear below. v,

The apparatus and functioning of the 'detailed features will now be set forth.

' Forms.

The forms iised in carrying out my inmade quadrangular and' with as much uniformity as possible and according to standard specifications and out of standard rolled shapes. For making a curved wall, or one diagonal or oblique to an intersecting wall, I use a form with Vparallel sides in which one side is wider than the other. In Figures 1 and 2 appear the simplest. form. Here the sides 9 are'united by a channel 10, the parts being preferably welded although they may be riveted, if desired. Each side 9 has, at one edge, a ball 11 and at the other a corresponding socket 12, the parts being shaped so that any ball of one form will fit any socket of another with a joint sufficiently tight to hold concrete and sufficiently loose to permit a ready sliding movement without binding and sufficiently rigid in its interlocking members to preclude lateral movement. Both the sides and channels are provided with suitable holes 13 for the hoisting tackle The channel 10 runs parallel to the balls 11 and preferably close thereto. The' length of each form is according to the depth to which the core wall is to be sunk, as is obvious.

In Figure 3 are shown some forms with external angles 14 holding bars 15 with balls 11 so that standard forms 4 may be secured thereto for intersecting walls or abutments.

In Figure 4 is shown a form 4 with sides 9 of unequal widths. This embodiment is suitable for curves.

In Figure 5 is shown an end form with two channels 10. This is desirable for starting because the parts are kept in fixed relation.

In Figure 11 -is shown a supplemental form 16 for use above the ground to give the top of the wall any desired shape. `Here the sides 17 are secured by tie rods 18, in the conventional manner.

In Figure 17 thel standard forms 4 rest on driving elements 19 of suitable form, which driving elements have vertical center holes 20 screw threaded at the top to receive a suitable driving pipe 21 through which, as well as the driving element 19, passes the driving plug 22 and this in turn is driven by the pile hammer 5. This embodiment is suitable for use in soft ground and soil with an abundance of ground water. When this structure is used, after the plug 22 is removed, concrete is passed through the pipe 21 and the pipe, element and form are progressively withdrawn, preferabl the filling and withdrawing are alternated.

In Figure 24 is shown joints connecting two forms. These `joints may be formed in any suitable way, but in the embodiment shown are formed by internal plates 23 which are perforated at the bottom with erforations 24 that register with correspon ing perforations 24 at the top of the lower form.

,ternal plate 31 Suitable bolts, or other holding means, may be passed through these perforations to keep the parts in proper alignment. Where such elongated forms are used, it is obvious that correspondingly lonO plugs and pipes must also be used, suitaile joints being made wherever necessary.

When the soil in which the wall is to be constructed is too moist for the structure shown and described above as to Figures 17 and 18, it is desirable to provide another structure which will nouv be described and which is shown in Figure 25. Here the pipe 21 is employed as the basis and to this are Secured the sides 25 and the ends 26 and 27.

The end 26 has two angles 28 with ovcrlap-,

ping ends connected by a plate 29 so' as to orm a dovetajl opening and the end 27 has .a corresponding plate 29 held in place by interior angles 30 and there is also an ext an opening corresponding' to the opening between the overhanging angles 28 thereby forming a dovetail joint. As many of these dovetailed ends are provided as are required and if necessary, the dovetail projections 31 may be carried on the side walls. This structure fits together with a very firm and tight .and rigid joint so that it may be used inthe softest soils. In this structure, the driving element 19 is secured at the lower end of each pipe 2l exactly as above described and the structure is operated in the same manner.

Filling,

ground water may be first blown out and before Vit has time to accumulate, relatively dry concrete is poured through the pipe and the pipe is thereafter withdrawn and thereafter fluid concrete is poured as before.

Rammng.

At times it is desirable to place the concrete on an enlarged foundation. When this occurs, the operation shown in Figure 9 is resorted to. Here a bedding of concrete 33, suitable for ramming, is deposited at the bot- `tom of a form 4, then the form is withdrawn a short distance and thereafter a ramming plug 34 with suitable guides 35 is put in this orm and driven by a hammer 5. The shape of the head 36 at the lower end of the ramming plug 34ay is such that the concrete 33 is spread in the desired directions laterally of -the axis of the form 4 so as to form an enlarged end 37, as indicated in Figures 13, 14 and 15, thus giving a greater bearing surface to the wall. Alfter this enlarged part is formed, as above described, the plug is with- Which is dovetailed so as todrawn and the form 4 filled and removed, as above set forth. The concrete 33 unites with the other concrete to form a monolithic mass.

Reinforcng.

ins

indicated, and when the forms are withdrawn these rods 38 flex or contract, that is their ends approach each other so that they overlap, and thereby reinforce each other, and the concrete longitudinally. It is obvious that for vertical reinforcement an number of straight rods may be suitably held 1n the forms 4 before the pouring and the concrete may be poured round them 1n the conventional manner. Furthermore, it 1S also obvious, that after the forms are withdrawn and before the concrete has set or hardened, it is possible to immerse reinforcing rods in almost any direction that-may be desired.

While I have shown and described certain embodiments of my invention, it is obvious that it is not restricted thereto, but that it is,

broad enough to cover all structures that come within the scope of the annexed claims.

What I claimis: 1. The method of forming a monolithic concrete structure within the. ground which consists in sinking interlocked three walled I forms which are closed by neighboring forms to. produce a series of cells, lling the cells with concrete, withdrawing the forms progressively to open the sides of the'adjacent forms thus causing the fluid concrete to flow and merge and thereby'fill the space occupied by the forms before removal.

2. The method of making a monolithic core wall which consists in progressively sinking linterlocked forms having parallel sides and one end wall open which are closed by neighboring forms to produce a series of cells, clearing the earthen material from the interior of the forms,` depositing` concrete of suitable fluidity in the cells thus formed and progressively withdrawing the forms prior to the setting of the concrete, thus causing the fluid concrete to fiow and merge. 3. The method of making a core wall which consists in progressively 'driving interlocked three wall forms, which are closed by neighboring forms to produce a series of cells, clearing the earthen material from the interior of the forms, depositing concrete of suitable fluidity in the bottoms of the cells thus formed, withdrawing the forms to about the upper level of this concrete, spreading the concrete laterally, furand progressively withdrawing the forms Jeu prior to the setting of the concrete, whereby a monolithic core wall is formed with an enlarged base.

4. The method of making a reinforced core wall which consists in progressively assembling interlocking forms, driving. the forms into the ground, clearing the earthen material from the interior of the forms, placing reinforcing in a contracted position in the forms with a tendency to spread laterally, depositing concrete of suitable fiuidity in the cells thus formed and about the reinforcing and progressively withdrawing the forms prior to the setting of the concrete thus causing the expanding of the reinforcing so that it overlaps` whereby a reinforced monolithic core wall is formed.

5. The method of making a monolithic core wall which consists in progressively driving interlocked three walled forms having two parallel sides which are closed by adjoining forms to produce a series of cells, clearing the earthen material from the interior of said cells, depositing concrete of suitable fluidit in said cells, progressively withdrawing t e forms prior to the setting of the concrete and then forming an extension of said core wall above the ground.

6. The method of forming a monolithic structure within the ground which consists of providing a unitary quadrangular form having one side open, interlocking a similar form with said first mentioned form to close said open side so as to form an inclosed cell, interlocking other similar forms in the same manner to form a plurality of such cells, sinking said interlocked forms, placing concrete in said cells and then withdrawing said forms prior to the setting of said concrete to cause merging of concrete masses.

7. The method of making a monolithic buttressed Wall which consists in sinking interlocked three sided forms which are closed by nei hboring forms to produce a series of cel s, then sinking interlocked forms of similar configuration so as to interlock with said first mentioned forms and produce a second series of cells at an angle to said first series, filling the cells wlth concrete and then withdrawing the forms progressively to open the sides of adjacent forms thus causing the fluid concrete to flow and merge.

In testimony whereof, I have hereunto set my hand this 15th day of October, 1927 HARRY B. ARDEN. 

